A/T Installation

- TOOLS REQUIRED
- SA9165T Oil Line Coolant Flusher
- SA91112T Axle Seal Protector
- SA9105E Engine Support Fixture

INSTALLATION
1. Flush transaxle oil cooler using SA9165T. (Refer to tool manufacturer's instructions, included with tool.)
2. Tap out EI module holes with a M6 x 1.0 mm tap.





3. Place transaxle securely on jack and position under vehicle. Install axle seal protector into both sides; use protector SA91112T. Raise transaxle high enough to connect shifter cable.





4. Connect shifter cable to transaxle gear selector lever and insert into converter housing.
5. Raise transaxle into vehicle.





6. Install two lower converter housing-to-engine bolts.
- Torque: 130 Nm (96 ft. lbs.)

NOTICE: Use caution not to damage seal while installing axle into transaxle.





7. Insert seal protector (indicated by the arrow) and install left-hand side axle into transaxle.
8. Remove seal protector.
9. Remove transaxle jack.





10. Insert seal protector and install intermediate shaft into transaxle.
11. After splines clear the seal protector but before snapping the axle into place, remove the seal protector tool.
12. Position intermediate shaft support and install two bolts.
- Torque: 54 Nm (40 ft. lbs.)
13. On DOHC (LL0) vehicles, position intake manifold support bracket and install intake bracket to intake manifold bolt.
14. Install intake bracket to intermediate shaft support nut.
- Torque: 54 Nm (40 ft. lbs.)
15. Perform cooler line flush using the oil line cooler flusher tool SA9165T. Follow the instructions printed on the tank for the proper procedure. This step must be done when rebuilding or replacing the transaxle in order to remove all debris.





16. Connect transaxle cooler lines to transaxle by pushing lines into cooler fittings until they bottom out.





17. Clean and lubricate ball joint threads.
18. Place cradle on lift and raise to vehicle. Place lower ball joint into knuckles when raising cradle up.

IMPORTANT: Make sure that the following parts are correctly positioned when raising cradle into vehicle.

a. Lower control arm bar studs to knuckle.
b. Cooling module support bushings.
c. Engine strut cradle bracket.
d. Transaxle mount.

NOTICE: Cradle-to-body guide pins must be used to maintain proper alignment. Alignment holes are at both front cradle mounting locations. Mount studs must be guided into holes in cradle as cradle is installed.





19. Install two rear cradle-to-body fasteners.

IMPORTANT: Do not tighten fasteners at this time.

20. Position cradle-to-body at the two front cradle to body fasteners.





21. Tighten four cradle-to-body fasteners.
- Torque: 210 Nm (155 ft. lbs.)
22. Remove powertrain support dolly.
23. Lower vehicle enough to allow underhood access and remove engine support bar SA9lOSE.





24. Install the transaxle strut, transaxle bracket-to-transaxle bolts (if removed).
- Torque: 54 Nm (40 ft. lbs.)





25. Install transaxle strut-to-midrail bracket fastener.
- Torque: 70 Nm (52 ft. lbs.)
26. Tighten transaxle strut-to-transaxle bracket fastener (if removed).
- Torque: 70 Nm (52 ft. lbs.)
27. Remove cooling module support wire.

NOTICE: Verify threads of bolts, mounting surfaces and threaded holes are clean and free of any residue. If using new bolts, make sure they are coated with yellow thread sealant. Otherwise, apply RTV Sealant (P/N 21006236) to bolt threads.





28. Install EI module and bolts.

NOTICE: Use extreme care when installing the electronic ignition (EI) module bolts. Make sure the bolt head is seated on the EI module when the torque specification is reached. If the bolt head is not seated on the EI module, remove the bolt and tap the hole to clean any debris from the threads.

- Torque: 8 Nm (71 inch lbs.)

NOTICE: Over-torquing of the ignition module will result in cracking the coil housing and damaging the coil.





29. Connect EI module harness connector. Push until a click is heard and pull back to confirm a positive engagement.
30. Connect spark plug wires to coil towers Press the spark plug wire boots firmly into place.

IMPORTANT: Orientation of the wires to the EI module is critical to the operation of both the module and on-board diagnostics The orientation is 4 1 2 3 respectively from left to right.





31. Install the top two converter housing-to-engine studs
- Torque: 100 Nm (74 ft. lbs.)





32. Connect harness connectors to transaxle.
a. Transaxle solenoid harness connector.

IMPORTANT: Do not over-tighten or damage to the connector plate may occur.

- Torque: 2.5 Nm (22 inch lbs.)
b. Vehicle speed and input speed sensors harness connectors.
c. Transaxle fluid temperature sensor harness connector.
d. Trans range switch harness connectors.
e. Two ground terminals to top two converter housing bolts.
- Torque: 25 Nm (19 ft. lbs.)
f. Ground wire to neutral (selector) switch.
g. Clip 02S-1 wire to converter housing.





33. Adjust control cable.
34. Install air cleaner and duct assembly.





35. Install battery tray.
36. Torque battery tray bolts.
- Torque: 10 Nm (89 inch lbs.)

IMPORTANT: One bolt is located in the fender well.

37. Install PCM and attachment bolts.
- Torque: 6 Nm (53 inch lbs.)

NOTICE: PCM connector bolt torque is critical.





38. Connect PCM J2 (black 28-way) connector and engage locking device.
39. Make sure battery tray is clean.
40. Make sure that the battery cable ends are clean and free of corrosion. (Clean with a wire brush.)
41. Make sure that the battery is in good physical condition (e.g., no cracks, or obvious damage) and that the terminals are clean.
42. Install battery carefully in the battery tray; make sure that the terminals do not short against any metal during the installation.
43. Install the battery hold-down retainer, locking the battery into the tray. Install and tighten hold-down retainer nut and screws.
- Torque: 9 Nm (80 inch lbs.)

CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED ON HOIST. TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE BEING REMOVED.





44. Raise vehicle on hoist.
45. Install transaxle lower mount-to-cradle fastener.
- Torque: 50 Nm (37 ft. lbs.)

IMPORTANT: To ensure proper powertrain alignment make sure that all other mounts have been torqued.





46. Install two engine strut cradle bracket-to-cradle fasteners.
- Torque: 50 Nm (37 ft. lbs.)





47. Remove steering gear support wire.
- Torque: 50 Nm (37 ft. lbs.)

IMPORTANT: For step 45, LHD illustration shown first, RHD Domestic illustration shown second.

48. Install steering gear-to-cradle attachment fasteners. (Power steering gear shown, manual similar.)





For RHD Domestic vehicles only.





49. Connect brake line-to-cradle retainer.





50. Install torque converter to flex plate bolts.
- Torque: 70 Nm (52 ft. lbs.)
51. Install dust cover and install dust cover to converter housing bolts.
- Torque 11 Nm (8 ft. lbs.)





52. Install engine to transaxle stiffening brace and install brace-to-engine and transaxle bolts.
- Torque 54 Nm (40 ft. lbs.)





53. Position exhaust manifold pipe into vehicle.
54. Install exhaust manifold pipe-to-exhaust manifold fasteners and tighten.
- Torque 31 Nm (23 ft. lbs.)





55. Install the intermediate exhaust pipe-to-three way catalytic converter flange fasteners.
- Torque: 25 Nm (18 ft. lbs.)





56. Install front exhaust pipe clamp support to engine stiffening bracket bolts and pipe clamp bolt, if removed.
Clamp Support to Engine Stiffening Bracket: Torque: 31 Nm (23 ft. lbs.)
Clamp Support to Front Exhaust Pipe: Torque: 60 Nm (44 ft. lbs.)





57. Install nut to lower ball joint, and torque.
- Torque: 75 Nm (55 ft. lbs.)
58. After torquing, if necessary, tighten nut additionally to align slot in the nut with the cotter pin hole in the ball joint. Install the cotter pin.

IMPORTANT: For step 56, LHD illustration shown first, RHD Domestic illustration shown second.





59. Install right side, left side, and front splash shield to cradle fasteners (LHD shown, RHD similar).





60. On coupes, install right and left lower fascia brace to cradle J-nuts.
- Torque: 10 Nm (89 inch lbs.)

NOTICE: Before installing wheels, remove rust or corrosion from wheel mounting surfaces and brake rotors/drums. Failure to do so can cause wheel lug nuts to loosen in service.

61. Position wheels onto hubs.
62. Install wheel nuts and tighten in a crisscross pattern. Repeat tightening pattern to be sure torque is correct.
- Torque: 140 Nm (103 ft. lbs.)

IMPORTANT: Clean and lubricate fastener with Saturn Transaxle Fluid. Wipe off excess fluid.

63. Install drain plug.
- Torque: 30 Nm (22 ft. lbs.)
64. Connect positive battery cable first.
- Torque: 17 Nm (13 ft. lbs.)
65. Connect negative battery cable last.
- Torque: 17 Nm (13 ft. lbs.)

IMPORTANT: Fill transaxle slowly or use a vented funnel.

66. Fill transaxle to proper level using Saturn Transaxle Fluid.
7.0L (7.4 US qt.)
67. Verify fluid level.
68. Before driving the vehicle after replacing or rebuilding a transaxle, use the service stall system or Scan tool to reset adaptive. Testing and Inspection
69. Perform vehicle wheel alignment.